10 th Russia & CIS Bottom of the Barrel Technology Conference and Exhibition (Russia & CIS BBTC) RSH Technology (TIPS RAS - CLG) for ultra-heavy feed processing Kadiev Kh.M. E-mail: kadiev@ips.ac.ru Moscow 23-24 of April, 2015 1
Oil refinery objective processing of heavy feedstocks. Oil conversion depth 80 million tons of fuel oil produced in Russia in 2014 80% were exported, only 20% left inside Russia. A clear trend outlined for reducing crude oil quality: high density, high viscosity, high content of metals, nitrogen, sulfur, higher acidity. That negatively influences the industry economy 2
Options for heavy residue processing Thermal and extractive processes Deasphaltization Delayed coking Visbreaking Bitumen production Catalytic processes Catalytic cracking Residue hydrotreating Hydrocracking -C +C In some cases refineries use a combination of the above processes in order to achieve optimum product slate 3
Ni+V metals, ppm wt% Increase of feed density increase in low value residue of thermal and extractive processes 2000 1800 Ni+V Металлы metals, Ni+V, ppm ppm Petroleum Кокс нефтяной, coke, % of на feed сырье S, % 45 40 1600 1400 1200 1000 800 600 400 200 35 30 25 20 15 10 5 0 0 0,98 0,99 1 1,01 1,02 1,03 1,04 1,05 1,06 Density, g/m3 4
Evolution of heavy feedstock heterogeneous catalysis Asphaltenes content, wt% 40 30 20 10 +C Fluid bed reactor (FCC) Fluid bed reactor or ebullioscopic Fixed-bed reactor Slurry reactor Head Water inc (LC-Fining) RDS «Chevron», Resid-fining, Resid HDS, Unicracking HDS, RCD «UOP Process», HDS «Shell» Blacking reactor H-Oil HRS-TIPS Slurry systems: H-Oil, Uniflex, LC-Fining, Eni slurry technology, VCC-KBR, HRS-TIPS. 1 10 100 1000 10000 Metals content, ppm 5
RSH technology TIPS RAS together with CLG developed a hydroconversion process with specialized ultra-disperse catalyst in order to process heavy oil feed (vacuum residues, atmospheric and vacuum residue of heavy and high viscosity crudes, bituminous crudes, natural bitumen, etc.). 6
Effective Particle Size, nm Polydiseprsity (PI) Synthesis of ultra-disperse catalyst Test unit for catalyst synthesis Catalyst particles size by DLS method (Brookhaven) 800 0,05 0,04 400 0,03 0,02 0,01 0 0 250 350 450 550 650 Run length, h Slurry Сларри catalyst катализатор PI catalyst (катализатор) Concentrated suspension of ultra-dispersed catalyst was produced for the first time 7
CLG s experimental facility for RSH process VRSH state-of-the-art laboratory facility could be used to further advance and accelerate the joint development and demonstration of RSH technologies: RU-85 was already successfully used in a joint 50-day TIPS-RAS/CLG demonstration of RSH in August-September, 2014 90%+ VR conversion demonstrated on Urals VR in recycle mode. RU-87 proposed in support of Yanos RSH Demonstration (2015).
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Test of TIPS s catalyst and slurry technology (CLG s pilot plant, Richmond USA. A single reactor system with residue recycle, 130 atm)
2 kg/h TIPS pilot plants for test of RSH (TIPS RAS) РДПС-2 PIC В-7 PIC FRC РРГ-1 В-1 РДПС-1 Загрузка сырьевой эмульсии Ф-1 Р-1 Л-3 I/ O Е-3 ВТВД TI Ф-2 РДДС-1 PIC Е-5 На АБГ 0,3 kg/h H 2 Е-1 Е-2 TI LI I/ O Л-1 В-2 На стенд На стенд TI TI TI I/ O I/ O I/ O TIRC В-6 На стенд Е-4 НТВД TI Е-6 Е-7 PR TIRC В-3 TI В-5 TIRC Сырьё Прекурсор катализатора Вода Н-1 В-4 I/ O Л-2 Тяжёлое масло На АБЖ В-8 Лёгкое масло На АБЖ FI ГЧ-1 Е-8 Е-9 Сырьевая эмульсия Охл. вода подача Охл. вода возврат На Свечу/ санитарную линию 11
Electron microscopy hydroconversion products research: catalyst particles fragments in reaction products 12 THF-insoluble residue Hydrogenate Layered structure of disperse phase can be clearly seen on side projection pictures as dark stripes (isolated or grouped in parallel) of 10-50 nm length and average layer cross-section of ~ 0.65 nm, which matches the tri-atomic layer of S-Mo-S.
Cooperative hydroconversion process of TIPS RAS and CLG is ready to be commercialized 1. Manufacturing technology for nano-sized catalyst is proven, pilot batch of catalyst was successfully tested on CLG s pilot plant. 2. Catalyst regeneration technology is commercially proven. 3. Hydroconversion process is executed on a well-proven commercial reactor platform LC-Fining. PROCESS DEVELOPMENT: Basic design developed together with CLG; detailed design of 50 KTA bituminous VR slurry hydroconversion demo unit is being developed for TATNEFT 13
General diagram of TIPS RAS hydroconversion process Hydrogen Urals VR 100% TIPS RAS catalyst Combined TIPS RAS hydroconversion LC-FINING reactor platform Conventional atmospheric distillation Fuel gas Naphtha Diesel VR recycle 40% Carrier Fresh Molybdenum (10%) Additives TIPS RAS catalyst preparation Regenerated catalyst Catalyst regeneration Electric power generation Conventional vacuum distillation LVGO HVGO Boiler feed water Ni+V concentrate 14
Orientation Diagram of TIPS RAS CLG Residue Slurry Hydrocracking (RSH) Process Hydrogen Fuel Gas Residue Crude Oil Vacuum Residue 100% Slurry Atmospheric Hydrocracker Fractionation Naphtha (RSH) Conventional Integrated Reactors Hydrotreater Jet Hydrocracker Vacuum Recycle 30-40% Fluxant TIPS RAS Catalyst Diesel Integrated Make Up. LVGO Hydrotreater Moly (10%) Catalyst Moly (90%+) Catalyst Vacuum Hydrocracker Preparation Recovery Fractionation TIPS RAS Recycle Power Conventional HVGO FCC Additives Generation Feed Boiler Feed water Ni + V + Fluxant 16
ECONOMIC EVALUATION 17
Integration of TIPS RAS technologies into existing refinery Study basis: Existing refinery processing 10,000 KTA Russian Export Blend (REB) Natural gas and MTBE available Power available at $0.066/kW-Hr Produce Euro IV gasoline / Euro V diesel Produce high sulfur fuel oil on Base Refinery (3,5% S / 380 cst) Cut fuel oil production after modernization; maintaining total refinery capacity Asphalt production on refinery per Base Refinery Cut its production after modernization; maintaining total refinery capacity Linear Programming (LP) modeling utilized; investment costs included in LP optimization 18
Base Refinery Note: Power consumption of Base Refinery is 50 MW; 11 MW produced by steam turbines, 39 MW from external grid. LPG Crude 10,000 KTA Crude Unit + Vacuum Unit Vacuum Residue to Fuel oil and Asphalt 10,000 KTA Light naphtha Heavy naphtha Distillates VGO Kero To fuel oil blending Naphtha HT Kero HT Diesel HT HT Light Naphtha HT Heavy Naphtha Jet HT Diesel Isomerization C5/C6 Reforming Isomerate Reformate Alkylate Naphtha Gasoline (8/80/12 92/95/97) LCO VGO HT HT VGO Diesel + Jet HCR Diesel PG + refinery fuel gas Hydrogen plant, 87 mln m3/day H 2 HCR bottoms FCC + Gas Plant C 3 /C 4 Alkylation FCC Gasoline FCC Gasoil Hgh sulfur Fuel Oil + Asphalt Vacuum Residue 19 H 2 S Sulfur Sulfur 19
Base refinery + TIPS RAS Hydroconversion Note: Power consumption of Refinery after modernization is 103 MW. 63 MW produced by steam turbines (52 MW by new ones + 11 MW by existing ones), and 40 MW from external grid = New process LPG Crude 10,000 KTA Vacuum Residue Crude Unit + Vacuum Unit 10,000 KTA Light naphtha Heavy naphtha Distillates VGO Kero To fuel oil blending Naphtha HT Kero HT Diesel HT HT Light Naphtha HT Heavy Naphtha Jet HT Diesel Isomerization C5/C6 Reforming Isomerate Reformate Alkylate Naphtha Gasoline (8/80/12 92/95/97) VGO to HCR LCO VGO HT HT VGO Diesel + Jet FCC Gasoil Steam from H2 plant TIPS RAS 2588 KTA + HT/HCR 2610 KTA UCO Metals recovery Naphtha Diesel HVGO PG + refinery fuel gas 52 MW (auxiliaries) PG + refinery fuel gas HCR Hydrogen plant Hydrogen plant HCR bottoms H 2 H 2 Diesel FCC + Gas Plant 20 C 3 /C 4 Alkylation FCC Gasoline FCC Gasoil to TIPS RAS process Sulfur, 62 H 2 S KTA Sulfur, 68 Fuel Oil + Asphalt Sulfur 20
Products balance Products Base refinery, KTA With TIPS RAS unit added, KTA + - LPG 113 159 +46 Naphtha 480 862 +382 Gasoline 1969 1953-16 Diesel 4374 6550 +2176 Pure products 6936 9524 +2588 High sulfur fuel oil 2851 0-2851 Sulfur 62 129 +67 Supplied to refinery from external sources Power, MW 39 40 +1 Natural gas, KTA 330 566 +236 21
Total installed cost Thousand Facility USD Light ends recovery 14 361 Naphtha desulfurization 5 286 Integrated hydrotreater 113 172 Hydrocracking with 95% conversion 117 436 TIPS RAS residue hydroconversion 489 433 H2 plant 183 929 Amine regeneration 13 229 Sulfur production 31 784 Power utilities + off-plot facilities 483 531 Total 1 490 319 22
Summary of Study Results Investment Cost (ISBL+OSBL), MMUS$ 1490 (1st Q, 2013, USGC) Net Incremental Revenue, MMUS$/Yr 807 (Relative to Base Refinery) Simple Payout, Years 1,85 23
Comparison of residue conversion options (made by CLG ): Delayed coking (DCU) (1) DCU + Coke burring boiler in circulating fluidized bed (CFB) (2) LC-FINING (СLG) (3) Options TIPS RAS hydroconversion (4,5) Case 0 (no Case 1 residue Coking processing) (DCU) Case 2, DCU + CFB Case 3, LC-FINING Case 4 TIPS + DCU Case 5 TIPS + boiler for residue burning Feed capacity, mln. t/y 7 000 7 000 7 000 7 000 7 000 7 000 Conversion, wt.% 67,0 87,0 87,0 85,1 95,0 94,0 Capital costs, mln. USD 2663,2 1362,3 1807,7 1630,7 2020,3 1842,2 NPV, mln. USD 157,0 48,6 99,6 183,0 265,9 272,4 Rate of return, years 9,2 11,7 9,5 6,2 5,5 5,1 24
Client s algorithm for use of TIPS CLG Residue Slurry Hydroconversion process with integrated hydrotreating - TIPS and Chevron pilot plant testing of representative sample of the Client s feedstock. Preparing initial data for the feasibility study---------- 2 months - Preparing a feasibility study of the efficiency of the TIPS CLG RSH process use on the Client s plant ---------2 months -Development of basic design of TIPS CLG RSH process with integrated hydrotreating ------------------------------------- 8-9 months - Detailed design development, construction and start-up of unit
Conclusions Basic and detailed design can be developed by Client s request in short time High quality processing of crude oil residue on a refinery using new technologies increases conversion rate to 90-95%. Adding TIPS RAS and CLG hydroconversion technology to refinery producing fuel oil: Allows for cutting fuel oil production Allows for increasing production of high value middle distillates Is economically attractive: Payout period is more than twice shorter in comparison to conventional DCU process Allows for effective transition to high viscosity and high sulfur, metals, asphaltenes and bituminous materials crude processing 26
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